Product category:
Tool and cutter grinding
News Release from: Walter GB | Subject: Helitronic five-axis CNC tool grinders
Edited by the Manufacturingtalk Editorial
Team on 12 May 2005
Modern CNC tool grinders ensure
prosperity
To keep pace with our customer demands a toolmaker has acquired modern CNC tool grinders to grind increasingly complex tooling to stay in business and thrive.
Sheffield, UK-based cutting tool manufacturer Sorby (UK) has increased its portfolio of Walter Helitronic five-axis CNC tool grinders to five machines with the addition of a Helitronic Mini Power with auto Pallet Loader Complementing four Helitronic Power machines, and Walter's Cyber Grinding tool simulation software, the Mini Power has been installed, says managing director Matthew Sorby, to increase capacity in the face of rising demand
This article was originally published on Manufacturingtalk on 20 Jun 2001 at 8.00am (UK)
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"With the machine's pallet loader able to hold up to 612 tools, we are taking full advantage of the Mini Power's ability to run unmanned - overnight and throughout the day - producing a variety of semi-standard drills, reamers and end mills in fairly large batches of up to 100-off," he says.
The machine accommodates tools up to 100mm diameter and up to 270mm long (for peripheral grinding) and up to 200mm long (face grinding).
Established in 1964 as L Sorby and Sons by Matthew Sorby's grandfather and father, the company has come a long way since it began manufacturing standard brazed lathe tools on manual machines in a cellar in Sheffield's city centre.
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The shift has been made by adopting the production of special-purpose tooling - often small batches - as well as 'partnering' a number of customers by holding tool stocks for them to call off (and pay for) on a consignment basis.
It has also seen Sorby (UK) maintain a small stock of drills, end mills, slot drills and reamers, which are supplied as standards (or semi-standards, after slight modification) to cement its single-source supply status with certain customers.
"To keep pace with our customer demands we recognised at an early stage that we needed modern tool grinders if we were to handle such tools - which are increasingly becoming more complex - and if we were to thrive, let alone stay in business," says Matthew Sorby.
Its first Walter Helitronic tool grinder was installed in 1996.
"At that time," he says, "we were producing a lot of special drills, and while most of the available CNC machines could produce, say, end mills, not all could handle the wide variety and types of special tooling we required".
"" One particular useful feature of the Helitronic machines highlighted by Matthew Sorby is the user-friendliness of the new generation PC-based HMC 600 control software that is common across the range.
This incorporates the Microsoft Windows XP operating system and the 2.4GHz processor (Pentium 4) provides maximum computing power via the easy-to-operate 15in TFT touch screen.
In Walter Window Mode, the control system assists the user in quickly creating programs for the regrinding of a number of tool types including cylindrical cutters, tapered cutters, drills and step drills, side and face milling cutters, stepped tools, profile tools, reamers and routers.
The control technology has been an important consideration in the company's repeated choice of Walter machines, says Sorby.
"Coupled with Walter GB's good level of back-up from its Redditch base, the user-friendliness and powerful functionality of the control technology - as well as the convenience of commonality of programming across the shopfloor - has been one of the reasons why we have always gone back to the Helitronics." One software program that has proved particularly useful is Walter's Package 2, which is used to produce the Sorby constant helix taper cutter designed for the production of intricate three-dimensional profiles, such as turbocharger impellers, where accuracy and surface finish are of prime importance.
The constant helix has the same cutting action along its entire length, unlike the varying geometry of constant lead cutters.
This means the cutting edge is always presented to the workpiece at the correct approach and rake angle, leading to reduced vibration/stress, better surface finish and improved tool life.
"By investing in the company when it needed it, we have not only maintained but also built on our impressive customer base in industry sectors like aerospace, automotive and motor racing throughout the UK and abroad," Sorby concludes.
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